My 1986 VF500F revival

Discussion in '1st & 2nd Generation 1983-1989' started by jstehman, Feb 2, 2021.

  1. jstehman

    jstehman New Member

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    I've been lurking around here for a while, since picking up the 07 VFR.

    Now I've done it and picked up a VF500F

    Thought I would share the progress and frustration I'm having with reviving a 35 year old Honda V4.

    Here's a really bad pic of the old girl. Just after purchase. Tank not attached. Blinker hanging. Tail plastic smashed. Side panels MIA.

    Wrong color scheme for front cowl, but at least it's there.

    She wasn't running when I bought her. I know I know.. but I was looking for a challenge. Kind of how I started with the Magna.

    I checked for oil before purchase and it was literally freezing outside and dark. You know, the perfect time to make vehicle purchases

    There's definitely something like petroleum of some kind in the crankcase. The owner showed the engine spun with the starter so at least we have that. Sounds like compression also, so bonus!

    Remember that old varnish gas smell?

    There's the tank dribbling out liquid nasty from the petcock. Nice

    Well let's just go ahead and drain whatever is in the crankcase and give her fresh oil and a filter. Hmm.. so that's where all the gas went!!

    And so it begins[​IMG]

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  2. jstehman

    jstehman New Member

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    Well isn't that lovely!

    Someone used a prybar to try and seat the carbs, and busted the airbox. Not once but twice! You can see the witness marks on the cross member.

    I have found that I have 85 carbs on this machine, and have found and installed a lower airbox to replace the damaged one. I may try and fill in the old one. Maybe

    On disassembly of the carbs, I found one pinched diaphragm. Thank goodness it wasn't torn and I was able to reseat and install with little issue. Also replaced a missing thrust spring between throttle shafts.

    Installed the carbs and spoon fed some gas and she runs!

    Not quite ready for the road.. still have valve clearances to check, chain and sprockets are toast, brakes need seals and cleaned, hydraulic cylinders need rebuilt, fork service...

    And that gas tank. And the petcock rebuild.

    [​IMG][​IMG]

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  3. Jim McCulloch

    Jim McCulloch New Member

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    Welcome to my Nightmare! Just kidding, nice bike, glad it actually ran. You are miles ahead now.
     
  4. jstehman

    jstehman New Member

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    Almost forgot about the cracked carb. There was definitely a vacuum leak here.

    Just look at that dent!

    I have since filled the crack with JB weld.[​IMG]

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  5. Jim McCulloch

    Jim McCulloch New Member

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    Amazing what idiots can do with an old bike, beer and a huge pry bar! That damage is unbelievable.
     
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  6. Captain 80s

    Captain 80s Member

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    Ribbed... for HIS pleasure.
     
  7. jstehman

    jstehman New Member

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    I got the replacement petcock screen in the mail today.

    It did Not come with the rubber piece in the middle that supports the screen on the fuel tube .

    I am trying to rejuvenate this twisted mashed piece I have in the Wintergreen/alcohol sauce

    I figured out part of the old screen is still stuck in the petcock opening of the tank. I will have to try and fish out the broken off piece from inside the tank.[​IMG][​IMG]

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  8. jstehman

    jstehman New Member

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    The seat cover is pretty comfy and in pretty decent shape too. Wrong color scheme but oh well

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  9. jstehman

    jstehman New Member

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    Rebuild kit upper right. Contains 2 pan head screws packing gasket and lower bowl oring.

    Disassembled petcock pic.

    Selector, wave washer, plastic washer and cover piece.

    The two rivets are actually cast into the petcock. Had a friend drill and tap these for me. (Thanks Paul!)
    Went all the way though in case I needed to run a bolt through and nut the end.

    I left my crappy packing piece in there for now, when the tank is ready I will use the new part.

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    [​IMG]
     
    Last edited: Feb 2, 2021
  10. Jim McCulloch

    Jim McCulloch New Member

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    I ended up buying an Oring kit from Harbor freight. I found one in the kit that fit the petcock filter perfectly.
     
  11. stewartj239

    stewartj239 Insider

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    I always love seeing projects like this for the 500. I agree that you are over a huge hurdle by getting it running. Keep the updates coming.
     
  12. jstehman

    jstehman New Member

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    I had some free time today, so I decided to hook up the Carbtune and see how out of whack my bench sync is.

    Not terrible. #2 was the most out. Of course, the Hardest screw to get to lol. Probably will go down as #1 in my "Honda bolt or screw from Hell". A toss up between the carb to airbox screws and the screws that hold the neutral light indicator to the block. Those things are just terrible!

    I got them mostly even.. #2 being a little higher than the rest.

    Still on the crappy cracking carb boots and a half assed carb clean plus unknown valve clearances so I'm just really messing around right now.

    Seems to run ok. Revs just fine. Dips a little below idle after a throttle whack, then evens out Might be rich a bit.. seems to idle better with the mixture screws closer to 3 turns out.

    Charging voltage is 15.5 at idle so there's that. Thinking of an FH012 for a replacement R/R. That one worked well on the Magna and they are pretty cheap.

    The list goes on

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  13. Captain 80s

    Captain 80s Member

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    With shit boots you're gonna always be chasing something. When you get fresh boots installed you're gonna probably be wise to put #40s in while the carbs are out.
     
  14. Captain 80s

    Captain 80s Member

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    Fixed it for you.
     
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  15. james vinson

    james vinson New Member

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    Wow, cool!
     
  16. jstehman

    jstehman New Member

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    Any trick tools to get at carb #2's sync screw?

    It's like the angle is too far down so the coolant crossover gets in the way.

    Tempted to unseat the carbs just to give it a tiny turn out then replace the boots and pilot jets while they are up.

    @Captain 80s
    35 is the stock pilot jets and #90 for mains I believe according to parts fiche. But carbjetkits are showing #105 as stock for mains..

    40 seems like a big jump. I trust your suggestion, and I'd love to hear the Why.

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    Last edited: Feb 4, 2021
  17. Captain 80s

    Captain 80s Member

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    #35 is stock for California, and is way too lean. #38 is stock for 49 state bikes, as well as 95/92 mains. Even stock VFs like a bump up on the pilots to #40. They start better and "warm up" faster, as in ready to pull away and ride. Full exhaust and K&N (and perhaps modified airbox) like #42.

    But a properly set up and tuned completely stock 500 can do just fine on #38, provided the pilot screw caps have been removed and/or the tabs removed for full range of adjustment. On that note, you can also swap the locations of the float bowls so the little tab is on the other side and can't prevent setting the pilot screws, allowing the bigger aluminum flat blade cap on the adjustment screw to stay in place and unmodified.
     
    Last edited: Feb 4, 2021
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  18. jstehman

    jstehman New Member

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    #40 pilot jets have been ordered.

    It's been Too Damn Cold to be in the garage working on the old girl. 9F yesterday!
    It's been in the negatives without wind-chill in the mornings here. Why do I still live in Nebraska??

    New parts waiting for install:
    Clutch master rebuild
    Front Brake Master rebuild
    Carb manifold boots
    Fuel petcock inlet screen/oring. Little rubber support thing for the inlet screen is still soaking in the secret sauce.
    Front and rear sprockets
    Drive chain

    I've been eyeballing this Honda carb sync tool 07908-ke7-0000 as a Valentine's gift from the wife .
    Look Honey! It works on both bikes! You're the best

    Shopping list:
    Fuel tank repair
    Fuel cap
    Fuel line from petcock to carb
    Fuel tank rubber mount piece for the rear of the tank under the seat
    Tires
    Brake caliper seals
    Wheel bearings.
    Hydraulic master cylinders rubber diaphragm covers
    Battery
    Regulator/rectifier

    The front cowling is off center by a bit. It looks like the inner fairing stay frame is bent where it attaches to the steering head, hopefully that is all that needs adjusting.

    I'll get to that when I take the radiator off because that needs inspected because it looks like it took a good hit at some point. It's not leaking at the moment and I'm not losing coolant. (Knock on wood) I will probably bring that to the shop that can *hopefully repair my fuel tank and just have it checked out.



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  19. jstehman

    jstehman New Member

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    Got the sync screw tool from Honda.

    It has a little whoop de doo at the end and is a 7mm hex driver with an internal cable attached to the handle.

    Very nice investment to help with syncing the carbs on these V4s. Spent Minutes getting her synced.[​IMG][​IMG]

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  20. jstehman

    jstehman New Member

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    I removed the carb rack today to replace the 38 idle jets for the 40s as recommended.

    Seems to run pretty well. Thanks for the suggestion Captain 80s

    Stupid me, I ordered all new orings for the coolant crossovers!

    All the work to get the carbs off and on, and I have to do it all over again when the parts arrive lol. SMH

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